Semiconductor device and formation method thereof

ABSTRACT

A method of forming a semiconductor device includes forming a gate structure over first and second fins over a substrate; forming an interlayer dielectric layer surrounding first and second fins; etching a first trench in the interlayer dielectric layer between the first and second fins uncovered by the gate structure; forming a helmet layer in the first trench; and filling the first trench with a dielectric feature.

PRIORITY CLAIM AND CROSS-REFERENCE

This application claims priority to U.S. Provisional Application Ser.No. 62/592,843, filed Nov. 30, 2017, which is herein incorporated byreference.

BACKGROUND

As the semiconductor industry has strived for higher device density,higher performance, and lower costs, problems involving both fabricationand design have been encountered. One solution to these problems hasbeen the development of a fin-like field effect transistor (FinFET). AFinFET includes a thin vertical ‘fin’ formed in a free standing mannerover a major surface of a substrate. The source, drain, and channelregions are defined within this fin. The transistor's gate wraps aroundthe channel region of the fin. This configuration allows the gate toinduce current flow in the channel from three sides. Thus, FinFETdevices have the benefit of higher current flow and reducedshort-channel effects.

The dimensions of FinFETs and other metal oxide semiconductor fieldeffect transistors (MOSFETs) have been progressively reduced astechnological advances have been made in integrated circuit materials.For example, high-k metal gate (HKMG) processes have been applied toFinFETs.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isnoted that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIG. 1 to FIG. 19C illustrate a method for manufacturing a semiconductordevice at various stages in accordance with some embodiments of thepresent disclosure.

FIG. 20A to FIG. 22C illustrate a method for manufacturing asemiconductor device at various stages in accordance with someembodiments of the present disclosure.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the provided subjectmatter. Specific examples of components and arrangements are describedbelow to simplify the present disclosure. These are, of course, merelyexamples and are not intended to be limiting. For example, the formationof a first feature over or on a second feature in the description thatfollows may include embodiments in which the first and second featuresare formed in direct contact, and may also include embodiments in whichadditional features may be formed between the first and second features,such that the first and second features may not be in direct contact. Inaddition, the present disclosure may repeat reference numerals and/orletters in the various examples. This repetition is for the purpose ofsimplicity and clarity and does not in itself dictate a relationshipbetween the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The apparatus may be otherwise oriented (rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly.

Fins may be patterned by any suitable method. For example, the fins maybe patterned using one or more photolithography processes, includingdouble-patterning or multi-patterning processes. Generally,double-patterning or multi-patterning processes combine photolithographyand self-aligned processes, allowing patterns to be created that have,for example, pitches smaller than what is otherwise obtainable using asingle, direct photolithography process. For example, in one embodiment,a sacrificial layer is formed over a substrate and patterned using aphotolithography process. Spacers are formed alongside the patternedsacrificial layer using a self-aligned process. The sacrificial layer isthen removed, and the remaining spacers may then be used to pattern thefins.

FIG. 1 to FIG. 19C illustrate a method for manufacturing a semiconductordevice at various stages in accordance with some embodiments of thepresent disclosure. Reference is made to FIG. 1. A substrate 110 isillustrated, and it may be a semiconductor substrate, such as a bulksemiconductor, a semiconductor-on-insulator (SOI) substrate, or thelike. The substrate 110 may be a wafer, such as a silicon wafer.Generally, an SOI substrate comprises a layer of a semiconductormaterial formed on an insulator layer. The insulator layer may be, forexample, a buried oxide (BOX) layer, a silicon oxide layer, or the like.The insulator layer is provided on a substrate, a silicon or glasssubstrate. Other substrates, such as a multi-layered or gradientsubstrate may also be used. In some embodiments, the semiconductormaterial of the substrate 110 may include silicon; germanium; a compoundsemiconductor including silicon carbide, gallium arsenic, galliumphosphide, indium phosphide, indium arsenide, and/or indium antimonide;an alloy semiconductor including SiGe, GaAsP, AlInAs, AlGaAs, GaInAs,GaInP, and/or GaInAsP; or combinations thereof.

A pad layer 120 and a mask layer 130 are formed on the substrate 110.The pad layer 120 may be a thin film comprising silicon oxide formedusing, for example, a thermal oxidation process. The pad layer 120 mayact as an adhesion layer between the substrate 110 and mask layer 130.The pad layer 120 may also act as an etch stop layer for etching themask layer 130. In some embodiments, the mask layer 130 is formed ofsilicon nitride, for example, using low-pressure chemical vapordeposition (LPCVD) or plasma enhanced chemical vapor deposition (PECVD).The mask layer 130 is used as a hard mask during subsequentphotolithography processes. A photo-sensitive layer 140 is formed on themask layer 130 and is then patterned, forming openings in thephoto-sensitive layer 140, so that some regions of the mask layer 130are exposed.

Reference is made to FIG. 2. The mask layer 130 and pad layer 120 areetched through the photo-sensitive layer 140, exposing underlyingsubstrate 110. The exposed substrate 110 is then etched, formingtrenches T1 and T2. A portion of the substrate 110 between neighboringtrenches T1 and T2 can be referred to as a semiconductor fin 150.Trenches T1 and T2 may be trench strips that are substantially parallelto each other. Similarly, the semiconductor fins 150 are substantiallyparallel to each other. In some embodiments, the trenches T1 is widerthan the trenches T2, such that there are different pitches between thesemiconductor fins 150. After etching the substrate 110, thephoto-sensitive layer 140 is removed. Next, a cleaning step may beperformed to remove a native oxide of the semiconductor substrate 110.The cleaning may be performed using diluted hydrofluoric (HF) acid, forexample.

After photo-sensitive layer 140 is removed, an isolation dielectric 160is formed to surround the semiconductor fin 150 over substrate 110. Theisolation dielectric 160 may overfill the trenches T1 and T2, and theresulting structure is shown in FIG. 3. The isolation dielectric 160 inthe trenches T1 and T2 can be referred to as a shallow trench isolation(STI) structure. In some embodiments, the isolation dielectric 160 ismade of silicon oxide, silicon nitride, silicon oxynitride,fluoride-doped silicate glass (FSG), or other low-K dielectricmaterials. In some embodiments, the isolation dielectric 160 may beformed using a high-density-plasma (HDP) chemical vapor deposition (CVD)process, using silane (SiH₄) and oxygen (O₂) as reacting precursors. Insome other embodiments, the isolation dielectric 160 may be formed usinga sub-atmospheric CVD (SACVD) process or high aspect-ratio process(HARP), wherein process gases may comprise tetraethylorthosilicate(TEOS) and ozone (O₃). In yet other embodiments, the isolationdielectric 160 may be formed using a spin-on-dielectric (SOD) process,such as hydrogen silsesquioxane (HSQ) or methyl silsesquioxane (MSQ).Other processes and materials may be used. In some embodiments, theisolation dielectric 160 can have a multi-layer structure, for example,a thermal oxide liner layer with silicon nitride formed over the liner.Thereafter, a thermal annealing may be optionally performed to theisolation dielectric 160.

Next, a planarization process such as chemical mechanical polish (CMP)is then performed to remove the excess isolation dielectric 160 outsidethe trenches T1 and T2, and the resulting structure is shown in FIG. 4.In some embodiments, the planarization process may also remove the masklayer 130 and the pad layer 120 such that top surfaces of thesemiconductor fins 150 are exposed. In some other embodiments, theplanarization process stops when the mask layer 130 is exposed. In suchembodiments, the mask layer 130 may act as the CMP stop layer in theplanarization. If the mask layer 130 and the pad layer 120 are notremoved by the planarization process, the mask layer 130, if formed ofsilicon nitride, may be remove by a wet process using hot H₃PO₄, and thepad layer 120, if formed of silicon oxide, may be removed using dilutedHF.

Next, as shown in FIG. 5, the isolation dielectric 160 is recessed, forexample, through an etching operation, wherein diluted HF, SiCoNi(including HF and NH₃), or the like, may be used as the etchant. Afterrecessing the isolation dielectric 160, a portion of the semiconductorfin 150 is higher than a top surface of the isolation dielectric 160,and hence this portion of the semiconductor fin 150 protrudes above theisolation dielectric 160.

It is understood that the processes described above are some examples ofhow semiconductor fins 150 and the STI structure are formed. In otherembodiments, a dielectric layer can be formed over a top surface of thesubstrate 110; trenches can be etched through the dielectric layer;homoepitaxial structures can be epitaxially grown in the trenches; andthe dielectric layer can be recessed such that the homoepitaxialstructures protrude from the dielectric layer to form fins. In stillother embodiments, heteroepitaxial structures can be used for the fins.For example, at least one of the semiconductor fins 150 can be recessed,and a material different from the recessed semiconductor fin 150 may beepitaxially grown in its place. In even further embodiments, adielectric layer can be formed over a top surface of the substrate 110;trenches can be etched through the dielectric layer; heteroepitaxialstructures can be epitaxially grown in the trenches using a materialdifferent from the substrate 110; and the dielectric layer can berecessed such that the heteroepitaxial structures protrude from thedielectric layer to form fins. In some embodiments where homoepitaxialor heteroepitaxial structures are epitaxially grown, the grown materialsmay be in situ doped during growth, which may obviate prior implantingof the fins although in situ and implantation doping may be usedtogether. In some embodiments, at least one of the semiconductor fins150 may include silicon germanium (Si_(x)Ge_(1-x), where x can bebetween approximately 0 and 100), silicon carbide, pure or substantiallypure germanium, a III-V compound semiconductor, a II-VI compoundsemiconductor, or the like. For example, the available materials forforming III-V compound semiconductor include, but are not limited to,InAs, AlAs, GaAs, InP, GaN, InGaAs, InAlAs, GaSb, AlSb, AlP, GaP, andthe like.

Reference is made to FIG. 6. A gate dielectric layer 170 is blanketformed over the substrate 110 to cover the semiconductor fins 150 andthe isolation dielectric 160. In some embodiments, the gate dielectriclayer 170 is made of high-k dielectric materials, such as metal oxides,transition metal-oxides, or the like. Examples of the high-k dielectricmaterial include, but are not limited to, hafnium oxide (HfO₂), hafniumsilicon oxide (HfSiO), hafnium tantalum oxide (HfTaO), hafnium titaniumoxide (HMO), hafnium zirconium oxide (HfZrO), zirconium oxide, titaniumoxide, aluminum oxide, hafnium dioxide-alumina (HfO₂—Al₂O₃) alloy, orother applicable dielectric materials. In some embodiments, the gatedielectric layer 170 is an oxide layer. The gate dielectric layer 170may be formed by a deposition processes, such as chemical vapordeposition (CVD), physical vapor deposition (PVD), atomic layerdeposition (ALD), plasma enhanced CVD (PECVD) or other suitabletechniques.

After the gate dielectric layer 170 is formed, a dummy gate electrodelayer 180 is formed over the gate dielectric layer 170. In someembodiments, the dummy gate electrode layer 180 may includepolycrystalline-silicon (poly-Si), poly-crystalline silicon-germanium(poly-SiGe), metallic nitrides, metallic silicides, metallic oxides, ormetals. In some embodiments, the dummy gate electrode layer 180 includesa metal-containing material such as TiN, TaN, TaC, Co, Ru, Al,combinations thereof, or multi-layers thereof. The dummy gate electrodelayer 180 may be deposited by CVD, physical vapor deposition (PVD),sputter deposition, or other techniques suitable for depositingconductive materials.

Next, the dummy gate electrode layer 180 and the gate dielectric layer170 are patterned to form dummy gate structures in accordance with someembodiments. For example, a patterned mask 190 is formed over a portionof the dummy gate electrode layer 180, as shown in FIG. 7. The mask 190may be a hard mask for protecting the underlying dummy gate electrodelayer 180 and the gate dielectric layer 170 against subsequent etchingprocess. The patterned mask 190 may be formed by a series of operationsincluding deposition, photolithography patterning, and etchingprocesses. The photolithography patterning processes may includephotoresist coating (e.g., spin-on coating), soft baking, mask aligning,exposure, post-exposure baking, developing the photoresist, rinsing,drying (e.g., hard baking), and/or other applicable processes. Theetching processes may include dry etching, wet etching, and/or otheretching methods (e.g., reactive ion etching).

An etching process is performed to form dummy gate structures DGwrapping the semiconductor fins 150 using the patterned mask 190 as anetching mask, and the patterned mask 190 is removed after the etching.The resulting structure is shown in FIG. 8. Each dummy gate structure DGincludes a gate dielectric layer 170 and a dummy gate electrode layer180 over the gate dielectric layer 170. The dummy gate structures DGhave substantially parallel longitudinal axes that are substantiallyperpendicular to longitudinal axes of the semiconductor fins 150, asillustrated in FIG. 8. The dummy gate structures DG will be replacedwith a replacement gate structure using a “gate-last” orreplacement-gate process.

Reference is made to FIG. 9. Gate spacers 210 are formed on oppositesidewalls of the dummy gate structures DG. In some embodiments, the gatespacers 210 may include silicon oxide, silicon nitride, siliconoxynitride, silicon carbide, silicon carbonitride, siliconoxycarbonitride, silicon oxycarbide, porous dielectric materials,hydrogen doped silicon oxycarbide (SiOC:H), low-k dielectric materialsor other suitable dielectric material. The gate spacers 210 may includea single layer or multilayer structure made of different dielectricmaterials. The method of forming the gate spacers 210 includes blanketforming a dielectric layer on the structure shown in FIG. 8 using, forexample, CVD, PVD or ALD, and then performing an etching process such asanisotropic etching to remove horizontal portions of the dielectriclayer. The remaining portions of the dielectric layer on sidewalls ofthe dummy gate structures DG can serve as the gate spacers 210. In someembodiments, the gate spacers 210 may be used to offset subsequentlyformed doped regions, such as source/drain regions. The gate spacers 210may further be used for designing or modifying the source/drain regionprofile.

Reference is made to FIG. 10. Epitaxial source/drain structures 220 arerespectively formed over portions of the semiconductor fins 150 notcovered by the dummy gate structures DG. The epitaxial source/drainstructures 220 may be formed using one or more epitaxy or epitaxial(epi) processes, such that Si features, SiGe features, silicon phosphate(SiP) features, silicon carbide (SiC) features and/or other suitablefeatures can be epitaxially grown in a crystalline state from theexposed portions of the semiconductor fins 150, and thus the exposedsemiconductor fins 150 are wrapped by the epitaxial source/drainstructures 220.

The epitaxy processes include CVD deposition techniques (e.g.,vapor-phase epitaxy (VPE) and/or ultra-high vacuum CVD (UHV-CVD)),molecular beam epitaxy, and/or other suitable processes. The epitaxyprocess may use gaseous and/or liquid precursors, which interact withthe composition of the semiconductor fins 150 (e.g., silicon, silicongermanium, silicon phosphate, or the like). The epitaxial source/drainstructures 220 may be in-situ doped. The doping species include p-typedopants, such as boron or BF₂; n-type dopants, such as phosphorus orarsenic; and/or other suitable dopants including combinations thereof.If the epitaxial source/drain structures 220 are not in-situ doped, asecond implantation process (i.e., a junction implant process) isperformed to dope the epitaxial source/drain structures 220. One or moreannealing processes may be performed to activate the epitaxialsource/drain structures 220. The annealing processes include rapidthermal annealing (RTA) and/or laser annealing processes.

In some embodiments, one or more epitaxy condition (e.g., epitaxialgrowth duration, and/or the flow rates of the gases used in theepitaxial growth) is controlled in such a way that epitaxial materialsrespectively grown from neighboring semiconductor fins 150 are merged.In this way, neighboring semiconductor fins 150 can be wrapped by asingle continuous epitaxial source/drain structure 220, which in turnresults in improved source/drain contact area and reduced source/draincontact resistance. However, merged epitaxial materials inevitablyincrease the volume of the epitaxial source/drain structures 220, whichin turn would lead to raised risk of damage to the epitaxialsource/drain structures 220 resulting from a cut metal gate (CMG)process performed at a later stage of fabrication. As a result, thepresent disclosure utilizes an additional helmet layer (e.g., layer 270as illustrated in FIG. 15B) to protect the epitaxial source/drainstructures 220 against the subsequent CMG process, which will bediscussed in greater detail below.

Reference is made to FIG. 11. An interlayer dielectric (ILD) layer 230is formed on the structure shown in FIG. 11. Afterwards, a CMP processmay be optionally performed to remove excessive material of the ILDlayer 230 to expose the dummy gate structures DG. The CMP process mayplanarize a top surface of the ILD layer 230 with top surfaces of thedummy gate structures DG, and the gate spacers 210. In some embodiments,the ILD layer 230 may include silicon oxide, silicon nitride, siliconoxynitride, tetraethoxysilane (TEOS), phosphosilicate glass (PSG),borophosphosilicate glass (BPSG), low-k dielectric material, and/orother suitable dielectric materials. Examples of low-k dielectricmaterials include, but are not limited to, fluorinated silica glass(FSG), carbon doped silicon oxide, amorphous fluorinated carbon,parylene, bis-benzocyclobutenes (BCB), or polyimide. The ILD layer 230may be formed using, for example, CVD, ALD, spin-on-glass (SOG) or othersuitable techniques.

In some embodiments, a contact etch stop layer (CESL) may be optionallyblanket formed on the structure shown in FIG. 10, and then the ILD layer230 is formed over the CESL layer. That is, there is a CESL between theisolation dielectric 160 and the ILD layer 230 and between the epitaxialsource/drain structures 220 and the ILD layer 230. The CESL may includea material different from the ILD layer 230. The CESL includes siliconnitride, silicon oxynitride or other suitable materials. The CESL can beformed using, for example, plasma enhanced CVD, low pressure CVD, ALD orother suitable techniques.

Reference is made to FIG. 12. The dummy gate structures DG are replacedby replacement gates structures RG. Herein, at least the dummy gateelectrode layer 180 of the dummy gate structures DG are removed to leavegate trenches between the gate spacers 210, and then the replacementgates structures RG are formed in the gate trenches. The replacementgates structures RG may include a metal 240. The metal 240 includes, forexample, tungsten, aluminum, copper, nickel, cobalt, titanium, tantalum,titanium nitride, tantalum nitride, nickel silicide, cobalt silicide,TaC, TaSiN, TaCN, TiAl, TiAlN, or other suitable materials.

In some embodiments, the metal 240 is a single-layered structure or amulti-layered structure. In some embodiments, the metal 240 includeswork function metals to provide a suitable work function for theconductive metal. In some embodiments, the work function conductivelayer may include one or more n-type work function metals (N-metal) forforming an n-type transistor on the substrate 110. The n-type workfunction metals may exemplarily include, but are not limited to,titanium aluminide (TiAl), titanium aluminium nitride (TiAlN),carbo-nitride tantalum (TaCN), hafnium (Hf), zirconium (Zr), titanium(Ti), tantalum (Ta), aluminum (Al), metal carbides (e.g., hafniumcarbide (HfC), zirconium carbide (ZrC), titanium carbide (TiC), aluminumcarbide (AlC)), aluminides, and/or other suitable materials. Inalternative embodiments, the work function conductive layer may includeone or more p-type work function metals (P-metal) for forming a p-typetransistor on the substrate 110. The p-type work function metals mayexemplarily include, but are not limited to, titanium nitride (TiN),tungsten nitride (WN), tungsten (W), ruthenium (Ru), palladium (Pd),platinum (Pt), cobalt (Co), nickel (Ni), conductive metal oxides, and/orother suitable materials. In some embodiments, the work functionconductive layer is formed by ALD process.

In some other embodiments where the gate dielectric layer 170 is alsoremoved during the removal of the dummy gate structures DG, thereplacement gates structures RG further includes a layer of gatedielectric (e.g., high-k gate dielectric layer with a dielectricconstant greater than about 3.9) formed over the structures of FIG. 11and into the gate trenches to resemble a U-shape profile, followed bydepositing the work function conductive layer and the conductive layerover the gate dielectric layer.

Reference is made to FIGS. 13A-13C, where FIG. 13A is a schematic viewof the semiconductor device according with some embodiments, FIG. 13B isa cross-sectional view taking along line 13B-13B of FIG. 13A, and FIG.13C is a cross-sectional view taking along line 13C-13C of FIG. 13A.Herein, a pad layer 250 and a hard mask layer 260 are formed on thestructure shown in FIG. 12. The pad layer 250 may act as an adhesionlayer between the ILD layer 230 and the hard mask layer 260. The padlayer 250 may also act as an etch stop layer for etching the hard masklayer 260. In some embodiments, the hard mask layer 260 is siliconnitride formed using, for example, low-pressure chemical vapordeposition (LPCVD) or plasma enhanced chemical vapor deposition (PECVD).

The hard mask layer 260 and underlying pad layer 250 are patterned usinga patterned photo-sensitive layer PR1. For example, a layer ofphoto-sensitive material can be coated on a blanket stack layer of hardmask material (e.g., silicon nitride) and pad material (e.g., siliconoxide), and then be patterned, using suitable photolithographytechniques, as the photo-sensitive layer PR1 with one or more openingsPO1. Afterwards, a portion of the blanket stack layer exposed by the oneor more openings PO1 is removed to form one or more trenches 260T in theblanket stack layer, resulting in formation of the patterned hard masklayer 260 and patterned pad layer 250 with one or more trenches 260T. Insome embodiments, after forming the patterned hard mask layer 260 andthe patterned pad layer 250, the photo-sensitive layer PR1 may beremoved using, for example, ashing.

Reference is made to FIGS. 14A and 14B, where the cross-sectionalposition of FIG. 14A is the same as the cross-sectional position of FIG.13B, and the cross-sectional position of FIG. 14B is the same as thecross-sectional position of FIG. 13C. With the pattern of the hard masklayer 260 including the one or more trenches 260T is created, one ormore trenches 230T corresponding to the one or more trenches 260T areetched into the ILD layer 230. The trench 230T of the ILD layer 230 isbetween the epitaxial source/drain structures 220. In some embodiments,the trench 230T may reach the isolation dielectric 160.

Herein, the metal 240 has a higher etch resistance to the etchingprocess of creating the trench 230T than that of the ILD layer 230, andtherefore the metal 240 remains substantially intact during the etchingprocess. The etching process may be an anisotropic etching process usingetchant gas with high selectivity between the metal 240 and the ILDlayer 230, so as to forming the trench 230T while keep the metalsubstantially intact. Moreover, the etchant gas is further selected tohave light molecular weight compared with etchant gas used in the laterCMG process. For example, the etchant gas with the light molecularweight includes, for example, fluoride-containing gases (e.g., CF₄, SF₆,CH₂F₂, CHF₃, and/or C₂F₆). The use of the etchant gas with the lightmolecular weight reduces undesired lateral etching and keeps thesidewall profile of the ILD layer 230 smooth and straight while it isetched. As a result, the trenches 230T may be accurately formed betweenthe epitaxial source/drain structures 220 while keep the epitaxialsource/drain structures 220 substantially intact, which in turn willresulting in reduced damage to the epitaxial source/drain structures 220during fabrication of the semiconductor device. In greater detail, thereare still portions of the ILD layer 230 remaining between sides of theepitaxial source/drain structures 220 and the trenches 230T, and thusthe epitaxial source/drain structures 220 are not etched during formingthe trenches 230T. In some other embodiments, after forming the trenches230T, the epitaxial source/drain structures 220 are exposed to thetrenches 230T. In some other embodiments, the epitaxial source/drainstructures 220 are etched during forming the trenches 230T.

Reference is made to FIGS. 15A and 15B, where the cross-sectionalposition of FIG. 15A is the same as the cross-sectional position of FIG.13B, and the cross-sectional position of FIG. 15B is the same as thecross-sectional position of FIG. 13C. A helmet layer 270 is blanklyformed on the structure shown in FIGS. 14A and 14B. The helmet layer 270covers sidewalls of the trenches 230T of the ILD layer 230 and sidewallsof the trenches 260T of the patterned hard mask layer 260. The helmetlayer 270 may be made of SiN, YSiO_(x), other suitable metalizedcompounds, or combination thereof. Herein, due to the substantiallyintact replacement gate structure RG, the helmet layer 270 is not formedbetween the fins 150 covered by the gate structure RG. In someembodiments, a thickness of the helmet layer 270 may be in a range of 2to 10 nanometers.

Reference is made to FIGS. 16A and 16B, where the cross-sectionalposition of FIG. 16A is the same as the cross-sectional position of FIG.13B, and the cross-sectional position of FIG. 16B is the same as thecross-sectional position of FIG. 13C. A CMP process is performed to thestructure shown in FIGS. 15A and 15B. Through the CMP process, the padlayer 250, the hard mask layer 260, and a portion of the helmet layer270 outside the trench 230T are removed.

Reference is made to FIGS. 17A and 17B, where the cross-sectionalposition of FIG. 17A is the same as the cross-sectional position of FIG.13B, and the cross-sectional position of FIG. 17B is the same as thecross-sectional position of FIG. 13C. Herein, a patterned hard masklayer 280 is formed over the structure shown in FIGS. 16A and 16B, witha patterned photo-sensitive PR2 thereon. The hard mask layer 280 fillsthe trench 230T and is thus embedded in the helmet layer 270. Thephoto-sensitive layer PR2 is patterned to define a position where a cutmetal gate (CMG) dielectric is to be formed. To be specific, a blanketlayer of hard mask material is etched using the patternedphoto-sensitive layer PR2 as etch mask, resulting in the hard mask layer280 having a trench 280T exposing the replacement gate structure RG anda portion of the hard mask layer 280 embedded in the helmet layer 270.

Herein, the opening PO2 of the photo-sensitive layer PR2 to define theCMG dielectric position is smaller than the opening PO1 of thephoto-sensitive layer PR1 to define the position of the helmet layer 270(as shown in FIGS. 13A-13C). To be specific, a width W2 of the openingPO2 of the photo-sensitive layer PR2 is less than a width W1 of theopening PO1 of the photo-sensitive layer PR1. For example, the width W2of the opening PO2 is less than the width W1 of the opening PO1 by athickness of the helmet layer, for example, 2 to 10 nanometers. Thewidth W2 of the opening PO2 is thus controlled in such a way that thehelmet layer 270 is free from exposed by the opening PO2. As a result,the helmet layer 270 will not be intentionally etched by the followingCMG process, which will improve the protection for the epitaxialsource/drain structures 220 against the CMG process.

Reference is made to FIGS. 18A and 18B, where the cross-sectionalposition of FIG. 18A is the same as the cross-sectional position of FIG.13B, and the cross-sectional position of FIG. 18B is the same as thecross-sectional position of FIG. 13C. A CMG process is performed to thegate structures RG through the opening PO2 of the photo-sensitive layerPR2 (referring to FIGS. 17A and 17B), such that a trench TG is formed tocut the gates structure RG into gates structures RG′. The CMG processperformed to the gate structure RG may include a wet etch, a dry etch,and/or a combination thereof. Etchants used in the CMG process may bedifferent from that used in the etching process as illustrated in FIGS.14A and 14B. As an example, a promising candidate for performing the CMGprocess includes an etchant gas with heavy molecular weight comparedwith the etchant gas used in the etching process as illustrated in FIGS.14A and 14B. For example, a dry etching process used in the CMG processmay implement chlorine-containing gas (e.g., Cl₂, CHCl₃, CCl₄, and/orBCl₃), bromine-containing gas (e.g., HBr and/or CHBr₃),iodine-containing gas, other suitable gases and/or plasmas, and/orcombinations thereof. The etchant gas with heavy molecular weight wouldincrease undesired lateral etching to the ILD layer 230, which wouldlead to undesired damage to the epitaxial source/drain structures 220.However, since an additional helmet layer 270 lines the sidewalls of thetrench 230T, the helmet layer 270 can protect the ILD layer 230 and theepitaxial source/drain structures 220 from the etchant gas with heavymolecular weight, which in turn will be advantageous to prevent thedamage to the epitaxial source/drain structures 220 resulting from theCMG process.

In greater detail, the etching process removes the portion of hard masklayer 280 embedded in the helmet layer 270 through the opening PO2 ofthe photo-sensitive layer PR2, resulting in a trench TD formed in thehelmet layer 270 and between the epitaxial source/drain structures 220.Herein, the etch resistance of the helmet layer 270 to the etchingprocess is higher than that of the ILD layer 230. Therefore, the helmetlayer 270 protects the ILD layer 230 from being damaged during formingthe trenches TG and TD. In some embodiments, the etch resistance of thehelmet layer 270 is higher than an etch resistance of the hard masklayer 280 to the etching. Herein, the trench TG is in communication withthe trench TD. A combined trench of the trenches TG and TD separates thereplacement gate structures RG′ from each other and separates theepitaxial source/drain structures 220 from each other. In someembodiments, after etching the replacement gate structure RG, thephoto-sensitive layer PR2 (referring to FIGS. 17A and 17B) may beremoved using, for example, ashing.

Reference is made to FIGS. 19A to 19C, where FIG. 19A is a schematicview of the semiconductor device according with some embodiments, FIG.19B is a cross-sectional view taking along line 19B-19B of FIG. 19A, andFIG. 19C is a cross-sectional view taking along line 19C-19C of FIG.19A. A dielectric material fills the trenches TG and TD to form adielectric feature 300 between the gates structures RG′ and between theepitaxial source/drain structures 220. The dielectric material may bedeposited by CVD, ALD, spin-on coating, or other suitable techniques.The dielectric material may include silicon oxide, silicon nitride,oxynitride, a dielectric material having a dielectric constant (k) lowerthan thermal silicon oxide (therefore referred to as low-k dielectricmaterial layer), and/or other suitable dielectric material layer. Thedielectric material may be different from that of the helmet layer 270.A CMP may be performed to polish back the dielectric material herebyprovide a substantially planar top surface of the dielectric feature 300with respect to the gates structures RG. As a result, the gate structurelines (e.g., the gate structures RG) are cut into the gate structuresRG′, and separated by the CMG dielectric (e.g., the dielectric feature300).

The dielectric feature 300 does not overlap the fins 150. For example,the dielectric feature 300 extends along the direction that the fins 150extend along. That is, the dielectric feature 300 has a longitudinalaxis in parallel with that of the fins 150. Herein, the helmet layer 270is not between the dielectric feature 300 and the gate structures RG′.For example, the dielectric feature 300 may be in contact with the gatestructures RG′ without the helmet layer 270 interposed therebetween. Insome embodiments, the helmet layer 270 is not between the dielectricfeature 300 and the gate spacers 210. For example, the dielectricfeature 300 may be in contact with the gate spacers 210 without thehelmet layer 270 interposed therebetween. Herein, the helmet layer 270extends from an edge of one gate spacer 210 adjacent to one gatestructure RG′ to an edge of another gate spacer 210 adjacent to anothergate structure RG′.

FIGS. 20A to 22C illustrate a method for manufacturing a semiconductordevice at various stages in accordance with some embodiments of thepresent disclosure. FIGS. 20A and 20B are at the stage similar to thatof FIGS. 14A and 14B, where the trench 230T is formed in the ILD layer230. The difference between the present embodiment and the embodiment ofFIG. 14A and FIG. 14B is that: the trenches 230T formed in the ILD layer230 exposes the epitaxial source/drain structures 220. Herein, a portionof the epitaxial source/drain structures 220 are etched during formingthe trenches 230T, and therefore epitaxial source/drain structures 220include substantially vertical facets exposed by the trenches 230T.Other details of the present embodiments are similar to thoseaforementioned, and not repeated herein.

Reference is made to FIGS. 21A and 21B, which are at the stage similarto that of FIGS. 16A and 16B. The helmet layer 270 is blankly formed anda CMP process is performed to remove a portion of the helmet layer 270outside the trench 230T. Herein, the helmet layer 270 covers exposedsurfaces of the epitaxial source/drain structures 220. The helmet layer270 may be in contact with the epitaxial source/drain structures 220without the ILD layer 230 interposed between. Other details of thepresent embodiments are similar to those aforementioned, and notrepeated herein.

Reference is made to FIGS. 22A-22C, which are at the stage similar tothat of FIGS. 19A-19C. The dielectric material fills the trenches TG andTD to form a dielectric feature 300 between the gates structures RG′ andbetween the epitaxial source/drain structures 220. The helmet layer 270separates the epitaxial source/drain structures 220 from the dielectricfeature 300. Other details of the present embodiments are similar tothose aforementioned, and not repeated herein.

Based on the above discussions, it can be seen that the presentdisclosure offers advantages. It is understood, however, that otherembodiments may offer additional advantages, and not all advantages arenecessarily disclosed herein, and that no particular advantage isrequired for all embodiments. One advantage is that the helmet layerprotects the epitaxial source/drain structures from damage resultingfrom the CMG process. Another advantage is that the process window forthe trench where the CMG dielectric is to be formed is increased. Yetanother advantage is that the merged epitaxial materials respectivelygrown from separate fins can be formed in an increased size, because themerged epitaxial materials can be protected from the CMG process by thehelmet layer.

According to some embodiments of the present disclosure, the method offorming a semiconductor device includes forming a gate structure overfirst and second fins over a substrate; forming an interlayer dielectriclayer surrounding first and second fins; etching a first trench in theinterlayer dielectric layer between the first and second fins uncoveredby the gate structure; forming a helmet layer in the first trench; andforming an dielectric feature in the first trench.

In some embodiments, the forming the dielectric feature is performedsuch that the helmet layer separates the dielectric feature from theinterlayer dielectric layer.

In some embodiments, the method further includes forming an isolationdielectric between the first and second fins before the forming the gatestructure, wherein the etching the first trench is performed untilreaching the isolation dielectric.

In some embodiments, the method further includes forming first andsecond source/drain features over the first and second fins uncovered bythe gate structure before the etching the first trench.

In some embodiments, the etching the first trench further exposes thefirst and second source/drain features.

In some embodiments, the forming the dielectric feature is performedsuch that the helmet layer separates the dielectric feature from thefirst and second source/drain features.

In some embodiments, the method further includes etching a second trenchin the gate structure, wherein the helmet layer has a higher etchresistance to the etching than that of the interlayer dielectric layer.

In some embodiments, the helmet layer is made of silicon nitride orYSiOx.

In some embodiments, the forming the helmet layer in the first trenchincludes conformally forming the helmet layer over the gate structureand the interlayer dielectric layer and removing a portion of the helmetlayer outside of the first trench.

According to some embodiments of the present disclosure, the method offorming a semiconductor device includes forming a gate structuresurrounding a plurality of first portions of first and second fins overa substrate; forming an interlayer dielectric layer surrounding aplurality of second portions of the first and second fins; etching afirst trench in the interlayer dielectric layer between the secondportions of the first and second fins; conformally forming a helmetlayer in the first trench; etching a second trench in the gate structurebetween the first portions of the first and second fins, wherein thehelmet layer has a higher etch resistance to the etching than that ofthe interlayer dielectric layer; and filling the second trench with adielectric feature.

In some embodiments, the etching the first trench is performed such thatthe gate structure remains on the first portions of the first and secondfins.

In some embodiments, the etching the second trench is performed suchthat the helmet layer is exposed.

In some embodiments, the method further includes forming first andsecond source/drain features over the second portions of the first andsecond fins respectively.

In some embodiments, the filling the second trench with the dielectricfeature is performed such that the dielectric feature is separated fromthe first and second source/drain features by the helmet layer.

In some embodiments, the forming the helmet layer is performed such thatthe helmet layer is not formed between the first portions of first andsecond fins.

In some embodiments, the method further includes forming an isolationdielectric between the first and second fins, wherein the etching thefirst trench is performed until reaching the isolation dielectric.

In some embodiments, the method further includes forming an isolationdielectric between the first and second fins, wherein the etching thesecond trench is performed until reaching the isolation dielectric.

According to some embodiments of the present disclosure, a semiconductordevice includes a substrate, a dielectric feature, gate structures, anda helmet layer. The substrate has first and second fins. The gatestructures are over first portions of the first and second finsrespectively. The dielectric feature is over the substrate and notoverlapping the first and second fins. The helmet layer is between thedielectric feature and at least one of second portions of the first andsecond fins.

In some embodiments, the dielectric feature separates one of the gatestructures from another of the gate structures.

In some embodiments, the semiconductor device further includes first andsecond source/drain features over the second portions of the first andsecond fins respectively, and the helmet layer separates the first andsecond source/drain features from the dielectric feature.

The foregoing outlines features of several embodiments so that thoseskilled in the art may better understand the aspects of the presentdisclosure. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

1-17. (canceled)
 18. A semiconductor device, comprising: a substratehaving first and second fins; a plurality of gate structures over aplurality of first portions of the first and second fins respectively; adielectric feature over the substrate and not overlapping the first andsecond fins; and a helmet layer between the dielectric feature and atleast one of a plurality of second portions of the first and secondfins.
 19. The semiconductor device of claim 18, wherein the dielectricfeature separates one of the gate structures from another of the gatestructures.
 20. The semiconductor device of claim 18, furthercomprising: first and second source/drain features over the secondportions of the first and second fins respectively, and the helmet layerseparates the first and second source/drain features from the dielectricfeature.
 21. The semiconductor device of claim 20, further comprising:an interlayer dielectric layer separates the first and secondsource/drain features from the helmet layer.
 22. The semiconductordevice of claim 18, further comprising: an interlayer dielectric layerbetween the helmet layer and said at least one of the second portions ofthe first and second fins, wherein the helmet layer separates theinterlayer dielectric layer from the dielectric feature.
 23. Thesemiconductor device of claim 18, further comprising: an isolationstructure between the first and second fins, wherein the gate structuresand the dielectric feature are over the isolation structure.
 24. Thesemiconductor device of claim 23, wherein a portion of the helmet layeris between the isolation structure and the dielectric feature.
 25. Thesemiconductor device of claim 24, wherein the portion of the helmetlayer is connected to the isolation structure.
 26. A semiconductordevice, comprising: a substrate having first and second fins; a firstgate structure over the first fin; a second gate structure over thesecond fin; a dielectric feature over the substrate and not overlappingthe first and second fins, wherein the dielectric feature has a firstdielectric portion between the first and second gate structures and asecond dielectric portion connected with the first dielectric portion;and a helmet layer surrounds the second dielectric portion of thedielectric feature.
 27. The semiconductor device of claim 26, whereinthe helmet layer terminates before reaching the first dielectricportion.
 28. The semiconductor device of claim 26, wherein the firstdielectric portion and the second dielectric portion are connected alonga direction that the first and second fins extends along.
 29. Thesemiconductor device of claim 26, wherein a top surface of thedielectric feature is substantially coplanar with a top surface of thefirst gate structure.
 30. The semiconductor device of claim 26, whereina top end of the helmet layer is substantially coplanar with a topsurface of the dielectric feature.
 31. The semiconductor device of claim26, wherein the first dielectric portion is connected with the first andsecond gate structures, the helmet layer is between the seconddielectric portion and at least one of the first and second gatestructures.
 32. The semiconductor device of claim 26, further com 33.The semiconductor device of claim 26, wherein the first gate structurecomprises a gate stack and a gate spacer on a sidewall of the gatestack, and the helmet layer is connected with the gate spacer.
 34. Asemiconductor device, comprising: a substrate having a fin; a gatestructure over the fin; a dielectric feature over the substrate and notoverlapping the fin; and a plurality of helmet portions between the finand the dielectric feature, and the gate structure separates the helmetportions from each other.
 35. The semiconductor device of claim 34,further comprising: a plurality of source/drain features over aplurality of first portions of the fin, wherein the gate structure overa second portion of the fin connecting the first portions of the fin,and the helmet portions separate the source/drain features from thedielectric feature, respectively.
 36. The semiconductor device of claim34, further comprising: an interlayer dielectric layer between at leastone of the helmet portions and the fin.
 37. The semiconductor device ofclaim 34, wherein at least one of the helmet portions surrounds thedielectric feature.